Manufacture of weftless cord fabric



July 8 1924. I 1.500234 M. CASTRICUM MANUFACTURE OF WEFTLESS CORD FABRIC Filed July 5, 1923 4,Sheets-Sheet 2 68 39 k J 0 5s INVENTOR.

A TTORNE Y.

July 8 1924.

M. CASTRICUM MANUFACTURE OF WEFTLESS CORD FABRIC Filed July 5, 1923 4 Sheets-Sheet 4 INVENTOR. WWW/MM BY 1 TTORNEY.

Patented July 8, 1924.

UNITED STATES PATENT OFFICE.

MARTIN CASTRICUM, F SPRINGFIELD. MASSACHUSETTS. ASSIGNOR TO THE FISK RUBBER COMPANY, OF CHICOIPEE FALLS, MASSACHUSETTS, A CORPORATION OF MASSACHUSETTS.

MANUFACTURE or wEFTLEss 0on1) FABRIC.

Application filed July 5,

To all whom it may concern:

Be it known that I, MARTIN CAsTRIoUM, a citizen of the United States of America, residing at Springfield, in the county of Hampden and State of Massachusetts, have invented certain new and useful Improvements in the Manufacture of l/Veftless Cord Fabric, of which the following is a specification. I

This invention relates to the manufacture of that class of material known as weftless cord fabric, in which a parallel series of separate, uninterwoven cords are laid side by side in an embedding matrix of rubber. Such fabric, as it is called for want of a better name, should have the parallel cords spaced evenly, without bunching or crowding, a matter of especial difficulty when the desired spacingleaves a considerable space between adjacent cords to be filled with rubber. It is the object of my invention to improve the manufacture of this fabric in various particulars of economy, accuracy, and facility which will appear more fully below; more particularly in the accurate control of the spacing of the cords in the finished rubber sheet. The invention will now be described in connection with the accompanying drawings, in which Fig. 1 is a. diagrammatic view illustrating the preferred manner of assembling the cords and embedding them in the rubber matrix;

Fig. 2 is a detail view taken from the line 2-2 in Fig. 3;

Fig. 3 is a section on line 3--3 of Fig. 2; Fig. 4: 1s a perspective detail of a portion ofthe cord guiding mechanism;

Fig. 5 is an enlarged detail on line 5-5 of Fig. 3;

Fig. 6 is a similar view showing a different position of adjustment;

Fig. 7 is a longitudinal section through an adjustable comb for guiding the cords;

Fig. 8 is a detail similar to Fig. 5 showing a modified form of the comb teeth;

Fig. 9 is a detail similar to Fig. 8 showinf the action of the comb in permitting the passage of a knot or splice;

Fig. 10 is a detail side elevation of that much of the mechanism illustrated in Fig.

Fig. 11 is a similar e but co r pe dillg to Fig. 6; i

1923. Serial No. 649,413.

Fig. 12 is a similar view showing the passage of a knot;

Fig. 13 is a detail illustrating the pre ferred manner of supplying the cords;

Fig. 14 is a detail side elevation of some of the mechanism shown in Fig. 2; and

Fig. 15 is a transverse section of a preferred form of comb wire.

In prior methods for the manufacture of weftless cord fabric much ditliculty has been experienced in securing accurate spacing of the cords where these are to be separated an appreciable distance in the finished sheet. Under these conditions the cords have a tendency to bunch or crowd into groups, leaving an abnormally wide-space between adjacent groups. This condition is of course undesirable, and it has been proposed to remedy it as by pressing the cords into contact with the rubber sheet by a grooved roller, but knots in the cords are liable to interfere with the use of the grooved roll. The present invention, among other things, aims to provide a more accessible and more easily controlled mechanism of this character; one in which the cords will not be subject to displacement on the passage of a knot even when a grooved roll is used; and one which can readily be adjusted, if necessary during the web-forming operation, so as to produce accurately any desired change in the spacing of the cords.

Referring first to Fig. 1, the cords a are supplied from a suitable creel 20, on which are mounted spools or tubes of cord as usual in warp-handling machinery, or which may be arranged as described hereafter. From the creel they are led through suitable aligning devices such as a thread board 21, tension rolls 22, and an adjustable expanding comb 23, all shown as of a type commonly met with in warp-handling machinery. This much of the mechanism simply serves as a supply to furnish a series of separate cords assembled side by side in rough sheet form. From this point the cords pass around a guide roll 24 and around a series of combined heating and equalizing rolls such as are fully described in my copending application, Serial No. 605,854, filed Dec. 7, 1922. These rolls are steam heated, simultaneously heating the cords to a temp'erature where they will unite firmly with he r er, and 1 4.6 t e their staggered an rangement causing the cords to become equalized in tension.

I have shown this much of the apparatus as located above a flooring 26, the remaining portion lying below this floor line on a flooring 27. The rubber coating operation consists in applying to the cords two op posed skim coats of rubber. For this purpose two ordinary three roll calenders 28 are used with a tension device 7 5 between them, the rubber feed being indicated at 29 in each case and the direction of rotation of the rolls being indicated by arrows. A single four roll calender may be used if desired, thus applying both skim coats simultaneously.

Attached to the first calender is a guide roll 30, directing the roughly spaced cords to a comb 31. The teeth of this comb are spaced sulficiently far apart so that a plurality (conveniently three) of the cords can pass in each dent or space between adjacent teeth. The teeth of the comb are made adjustable, conveniently in a manner common in textile machinery and therefore not necessary to describe in much detail. An adjustable comb of this character has been shown in Fig. 7 with a portion of its casing 32 removed to disclose the construction. The teeth of the comb are perforated to receive wires 33, upon which are threaded interlaced coil springs 34. End pieces 35, also threaded on wires 33, serve to extend the springs when they are drawn apart by a right and left screw 36. By varying the degree of extension of the springs, the spacing of the teeth of the comb will be varied unlformly as desired.

Comb 31, as well as certain other parts to be described below, are mounted upon slides 37 (Figs. 2 and 3) which have a limited movement toward and from the central calender roll in suitable ways 38 formed in brackets 39. To move the two slides simultaneously they are provided with threaded lugs 40, through which pass screws 41 journaled in brackets 39 and secured against endwise movement. Each screw has fixed to its end a worm wheel 42 meshing with a worm 43 on a cross shaft 44 suitably jour naled in the calender frame. At one end this shaft has a hand wheel ll), by means of which, through the described train of mechanism, the slides 37 may be shifted. As will be apparent in Fig. 3. the brackets 39 have been in the illustrated form of the invention mounted at an angle to the horizontal. This is not necessary to the operation of the mechanism, nor does it affect its functioning, but is useful in cases where the calenders are to be used for other purposes than the production of weftless fabric, as more space is thereby afforded under the parts supported by the bracket. In cases whe the c l nd rs are sed so ly for the production of weftless cord fabric I prefer to mount the brackets horizontally so as to give readier access to the cords as they pass through the several guiding devices.

From the wide dent comb 31 the cords pass under a stationary cylindrical bar 46 fixed in the slides, and are thereby tensioned and smoothed out preparatory to their final arrangement and coating. From the stationary bar the cords pass through a comb 47, adjustably supported in the slides in a manner to be described, and adjustable as to spacing in the same manner as comb 31. The particular construction of this comb and its cooperation with the remaining mechanism form an important part of the present invention, and a consideration of this feature will be temporarily postponed. The cords after leaving the second comb which is arranged with one cord to a dent instead of three) lie upon a roller 48 freely rotating in journals in the slides, and pressing when the slides are in their inner position against the rubber sheet 49 on the middle calender roll 50. As a convenience in operation the adjusting shafts 36 of the two combs are connected together by sprockets 51 and a chain 52, so that by turning a handle 53 on one of the sprockets (Fig. 14) both combs can be adjusted together in accurate relation with each other.

The relation of comb 47 to roll 48 will now be considered in detail. As stated initially, one of the main purposes of this invention is to guide the cords to the rubber sheet accurately and with any desired spacing, and so that the presence of knots will not interfere with the accuracy of the work. The preferred form of tooth for this comb will be best understood from a comparison of Figs. 5. 10, and 15. Looked at from the side (Fig. 10) the wire is rectangular, looked at from the top (Fig. 5) it is tapered towards its free end, and in section (Fig. 15) it is a sharp oval. with one edge (preferably the more pointed one) pre sented to the oncoming cords.

The taper of the wires accomplishes several purposes, the first to be considered being that of adjustability for different cord spacing or different cord diameter. For the purpose of this adjustability this comb is carried by studs 55 screwed into portions of the slides 37 and passing through slots in the comb casing. By loosening the studs the comb can be slid in the direction of its wires either up or down, and the studs may then be tightened to clamp the comb in the desired adjusted position. Figs. 5 and 10 on one hand, and Figs. 6 and 11 on the other, show two different positions of adjustment of the comb wires. The effect of the adjustment is best seen in Figs. 5 and 6. Fig. 5 may be for purposes of comparison con sidered the normal position. In Fig. 6 the I comb is lowered relative to the sheet of cords to accommodate cords of larger diameter with the same center to center spacing. On account of the tapered form of the teeth the lowered position of the comb causes a less width of each tooth to be presented in. the plane of the cords, leaving for the same center to center spacing a larger space to be filled by the cords. Preferably the comb is soset that the cords have an easy sliding fit between the teeth, as this insures absolute regularity of cord spacing. It is of course possible to make the comb wires straight instead of tapered as indicated in Figs.;8 and 9, but this eliminates the advantage of adj u'stability. Also the adjustable feature, if used, may be employed in connectiori with the regular comb wire spacing adjnstinent to preserve the proper fit between the wires and the cords as the spacing of the wires is varied. The tapered form of wire is preferred to the straight both on account of its adaption for adjustability and because of its flexibility in the passage of knots. l v

The cord as it leaves the comb 47 is substantially in contact with the curved surface of roll 48. This is accomplished by the slanting position of the comb with respect to the line of travel of the cords, and functions to guide the cords in accurately spaced relation up to the last possible moment before contact with the roll. After the cords are once safely on the surface of roll 48 there is no danger of further displacement, and as they are pressed while still on this roll into adhering contact with the sheet of rubber there isno time between the passage of the cords through the comb and their contact with the rubber when they are not positively held against displacement.

I The slanting arrangement of the comb has a further advantage in relation to the handling of knots. These knots in practice occur principally in joining one spool or cone of cord to a succeeding one and are in general not detrimental in the product. They have, however, caused considerable difficulty in the formation of the weftless fabric by displacing adjacent cords or by catching in the apparatus with consequent breakage either of parts of the machinery or of the cords. The manner in which these dangers are avoided can be understood best from a description of the passage of a knotted cord through the guiding mechanism. A knot can pass easily through comb 31, as that comb has its wires arranged relatively far apart. When the knot reaches comb 47, however, it cannot pass directly through owing to the fact that the cord itself just fills the space between adjacent teeth. Due to the slanting arrangement of the comb, however, the knot b (Fig. 12) rides up the edge of adjacent wires until it reaches a p int above the other cords. hen it has reached this point the comb wires upon which it rests are unsupported by the other cords, and flex outwardly Fig. 9) permitting the knot to slip through. Due to the overlapping relation of the free ends of the comb teeth to the roll 4.8 as shown in 3, the knot falls directly on said roll. The tension of the cord with the knot in it causes this action to take place with a snap, whereupon said cord is immediately supported on the roll in parallel relation with the other cords. Thus a grooved roll may be used with no danger of a knot displacing adjacent cords as they enter upon the grooved roll. It will be seen that the comb separates the cord with a knot in it, raises it above the plane of the other cords until the knot rides over the comb, and then permits it to fallin proper osition on a support which is designed to maintain such position until the rubber takes hold. If a grooved roller is used in place of the plain roller 48, a knot in one cord will be dropped on top of the adjacent cords, instead of crowding between them as in the former use of the grooved roller, thus avoiding any danger of the knot forcing these adjacent cords out of their respective grooves. If the tapered wires of the preferred type are used the increased space between the wires nearer their ends also assists in allowing the passage of the knot. This action is accomplished without any harmful strain upon the apparatus or cords, as the cord is sufficiently extensible to accommodate itself readily to the slight increase in its length of path.

In Fig. 18 I have shown an optional but preferred manner of supplying the cords on the creel. In this form, which is standard practice in certain textile operations, there are two supporting posts 60 provided for each cord, upon which are mounted cones 61 of cord. This cone type of winding differs from the usual spool or tube winding in that the cord at can be pulled off in substantially the direction of the axis of the cone, as shown, rather than being drawn off tangentially, the cone remaining stationary in stead of revolving. The cord passes through a tensioning eye or pigtail guide 62 and through suitable other guides 63 to the as sembling devices. The advantage of this manner of supply lies in the fact that, since the cones do not revolve, the inner end 64 of the cord on one cone can be tied at 65 to the outer end 66 of the cord on the second cone. When the cord on one cone is exhausted the mechanism immediately begins to draw from the second cone. As the cones do not revolve the tying of the knots is a simple matter, which can be accomplished at any period of operation, and tying of traveling cords, as in the usual spool type of creel, is avoided. It is preferable in Winding these cones to have the end. 6%. coiled around.

the supporting tube several times before the winding proper is commenced, so that a sufficient length is provided for easy tying.

Having thus described my invention, I

' claim 1. In combination, a'roll adapted to support a sheet of rubber, a roll adapted to carry a sheet of cords upon its surface and present them to the rubber sheet, and cord guiding devices for arranging the cords parallel and evenly spaced on the surface of the secondnamed roll comprising a comb having adjacent teeth spaced to receive a plurality of cords, an evening surface over which the cords pass, and a comb positioned close to the second-named roll and having adjacent teeth spaced apart substantially the thickness of a single cord.

2. In combination; a roll adapted to support a sheet of rubber; a roll adapted to carry a sheet of cords upon its surface and present them to the rubber sheet; and cord guiding devices for arranging the cords parallel and evenly spaced on the surface of the second-named roll comprising a comb having adjacent teeth spaced to receive a plurality of cords, an evening surface over which the cords pass, and a comb positioned close to the second-named roll and having adjacent teeth spaced apart substantially the thickness of a single cord, said second-named comb being arranged at a slant to the line of travel of the cords.

3. In combination, a roll adapted to support a sheet of rubber, a roll adapted to carry a sheet of cords upon its surface and present them to the rubber sheet, and cord guiding devices for arranging the cords parallel and evenly spaced on the surface of the second-named roll comprising a comb having adjacent teeth spaced to receive a plurality of cords, an evening surface over which the cords pass, and a comb positioned close to the second-named roll and having adjacent teeth spaced apart substantially the thickness of a single cord, said second-named comb being arranged at a slant to the line of travel of the cords and positioned so that its guiding wires are substantially tangent to the second-named roll close to the line of tangency of the cords therewith.

4. A cord guiding device comprising a roll, a comb adjustable as to spacing arranged substantially tangent therewith, and

spacing in cords may be accommodated with a desired clearance between the cords and adjacent comb wires.

6. An apparatus for guiding parallelcords to a rubber coating calender comprising a roll upon which the cords may be arranged exactly as they are desired for coating and a comb for so arranging them, said comb having the free ends of its teeth extending toward the roll in overlapping relation therewith, all constructed and arranged so that a knot in a cord will ride along the extended ends of theteeth, spread them and drop onto the roll while maintaining its parallel relation with other cords.

7. An apparatus for the purpose described comprising a rubber coating calender, a roll adjacent one of the calender rolls to apply parallel cords to the rubber on the calender, a comb having its teeth extending tangenti ally of said roll with their free ends slanting in the direction of the cord travel and in overlapping relation to said roll.

8. A cord guide comprising a roll to support cords in parallel relation, a comb having its teeth secured together at one end only, the free ends of its teeth slanting toward the travel of the cords to the roll and overlapping said roll.

9. An apparatus of the class described comprising a roll, a comb having teeth the free ends of which are resilient, said teeth being arranged in slanting relation toward the roll and in overlappingrelation thereto.

10. An apparatus for joining fillerless cord and rubber comprising a calender, devices to arrange the cords in parallel relation and in sheet formation adjacent the calender. means to maintain the parallel relation until the cords join the rubber, and means associated with said devices to force aknotted cord out of the plane of the other cords while the latter are fed to said maintaining MARTIN CASTRICUM. 

